Optimization of Polylactic Acid (PLA) Fiber Production Processes and Its Applications in the Textile Industry

Polylactic acid (PLA) fiber, as an environmentally friendly bio-based material, has become a research hotspot in the field of polymer materials, particularly regarding its production processes and innovative applications in the textile industry. This paper systematically examines PLA fiber synthesis pathways, optimization of spinning processes, and novel applications within the textile sector. I. Breakthroughs and Optimization in Production Processes Raw Material Preparation Pathways Lactic acid—the primary raw material for PLA fiber—is predominantly produced via fermentation, using high-starch crops such as corn and cassava as substrates. Through microbial metabolic conversion, L-lactic acid is obtained. Compared with petroleum-based synthesis, the fermentation route achieves over 85% raw material utilization efficiency and reduces lactic acid production costs by approximately 30% per ton. Currently, domestic enterprises widely adopt continuous fermentation processes, employing dynamic pH control and directed microbial strain domestication to shorten fermentation cycles to under 48 hours. High-Molecular-Weight PLA Synthesis Process Industrial-scale PLA synthesis primarily relies on the ring-opening polymerization of lactide, comprising two critical stages: Lactide Purification: Molecular distillation technology elevates the purity of the lactide—produced via dehydration and cyclization of lactic acid—to above 99.5%, significantly minimizing residual monomer interference in subsequent polymerization steps. Controlled Polymerization: Using catalysts such as stannous octoate and a gradient temperature polymerization process (120–180°C), PLA resins with molecular weights exceeding 100,000 g/mol can be achieved. Their melt flow rate remains stable at 8–15 g/10 min (190°C/2.16 kg), meeting requirements for spinning processing. Innovations in Melt Spinning Processes The mainstream industrial process employs a two-step melt spinning method: Spinning Temperature Control: Zone-wise die temperature control precisely maintains spinning temperatures between 210–230°C—preventing thermal degradation while ensuring adequate melt fluidity. Drawing Process Optimization: Under a spinning speed of 1000 m/min, post-drawing at a draw ratio of 3.5 enhances fiber tensile strength to 4.1 cN/dtex and achieves a crystallinity of 45%. Research indicates that integrating an online crystallinity monitoring system enables control of fiber diameter fluctuations within ±0.5 μm.

Diversification of Polylactic Acid Products: Market Evolution from Disposable Tableware to Premium Textiles

PLA’s application in disposable tableware was among the earliest to attract widespread attention. Due to the persistent environmental pollution caused by non-biodegradable conventional plastic tableware, PLA—owing to its fully biodegradable nature—has emerged as an ideal substitute. Although initial adoption faced challenges such as relatively high cost and insufficient heat resistance, technological advancements—including PLA modification—have significantly improved its thermal stability and mechanical strength. Today, PLA tableware meets diverse usage requirements, including food delivery services, large-scale events, and airline meals; moreover, it fully degrades in natural environments, substantially reducing plastic waste generation. In the medical field, PLA demonstrates unique value—for instance, in surgical sutures, bone fixation pins, and controlled-release drug carriers. Its excellent biocompatibility and bioresorbability eliminate the need for secondary surgeries to remove implants, thereby alleviating patient discomfort and accelerating postoperative recovery. Additionally, PLA is used to manufacture disposable medical supplies such as masks and protective gowns—ensuring safety and harmlessness while mitigating the environmental burden associated with medical waste. PLA’s application in textiles represents another pivotal milestone in its diversification. Through specialized processing techniques, PLA fibers (e.g., PLA filament) are transformed into apparel fabrics exhibiting superior breathability, softness, and luster—comparable to both conventional synthetic and natural fibers. These fabrics not only deliver exceptional wearing comfort but also offer fashion industries a viable pathway toward reducing environmental footprints through biodegradability. From sportswear to high-end fashion, PLA-based textiles are increasingly becoming emblematic of eco-conscious trends—fulfilling growing consumer demand for sustainable fashion.

Corbion seeks to reintroduce PLA to textiles

Oct 15, 2026

TotalEnergies Corbion aims to reintroduce polylactic acid (PLA) into textile applications by improving filament production to address past durability limitations. This initiative seeks to establish PLA as a viable bio-based polymer alternative in the apparel sector.

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